IMA Displays Novel Process Technologies

Machine manufacturer IMA is showcasing a number of technological advances for the processing and packaging of pharmaceutical products at ACHEMA 2015. The company’s solutions include a new way to design freeze dryers and accelerating the freeze-drying process.

Solid dosage manufacturing and packaging

The ADAPTA 200 high-speed capsule filler, with its flexible design, allows dosing of up to three products into the same capsule without affecting the maximum speed of 200,000 capsules/hour. Its dosing units can be easily removed and are reversible/interchangeable, giving the possibility of a plug and play shift between different machine configurations and filling combinations. ADAPTA 200 can achieve the 100% control gross and/or net weight, integrated with automatic feedback on machine parameters and rejection of out of limits capsules.

MYLAB, designed for granulation and coating processes, is suitable for R&D and scale up purposes. This new equipment consists of a main technical unit (MTU) with a fully integrated air handling unit and control panel, connected to a removable processing module, represented either by a coating pan or by a fluid bed processor. The coating pan processor is equipped with an interchangeable and fully perforated drum able to work batches from 1.5 to 6 litres. The fluid bed processor has interchangeable product containers for top or bottom spray processes, which can run batches from 2 to 6 litres. MYLAB can serve as a laboratory unit as well as a machine for small production batches, with flexibility and easy scale up. Characterized by small overall dimensions, MYLAB is portable on wheels and can be easily and quickly connected to the utilities.

Both ADAPTA and MYLAB feature the XIMA HMI. According to IMA, the system has been awarded the A’ Design Award for its application of design principles with the aim of improving user experience. Based on the four principles of linearity, intuitiveness, iconicity, and scalability, the HMI plays a strategic role in improving operators’ efficiency, providing prompt responsiveness, enhanced process knowledge, and predictivity, as well as easy learning for new operators.

The SPINE HYPO is the new SPINE machine with containment design for automatic inspection and sorting of highly potent tablets and capsules. It features containment strategies, such as separation of process area with barrier, negative pressure, air filtering, gloves, RTS ports, closed feeding, and discharging and last but not least, dry and wet cleaning in containment.

PATVIS APA is a process analytical technology visual inspection system for monitoring, understanding, and optimization of fluid bed pharmaceutical production processes. This system enables real-time monitoring and fully automated analysis of size and shape of particles throughout processing. It is portable and can be easily integrated to existing viewing ports for in-line inspection or used as a standalone device for at-line or off-line inspection.

IMA’s new SP2 multichannel electronic counter for tablets and capsules has a smaller footprint and offers increased output. This new counter has an integrated conveyor controlled from a single HMI. Quick changeover components and the tabletop design improve the machine’s ease of cleanability. The machine on show at ACHEMA is also equipped with the advanced counting technology EFS.

The C80HS-A76 is an integrated blister line designed especially for the production of medium batches and frequent size changeovers. The C80HS-A76 reaches a production speed of up to 700 blisters/minute and 250 cartons/minute. The C80HS has the flexibility to be connected also with the A86 cartoner able to reach 350 cartons/minute and the A96 cartoner able to run up to 500 cartons/minute. C80HS features a positive blister transport and an innovative blister cutting system.

Aseptic processing  

Among the new solutions on display is the IMA LIFE filling and stoppering of ready-to-fill disposable syringes. Compliant with the most recent cGMP and FDA regulations, the machine is tailored to the latest requirements of the pharmaceutical and biotechnology industry in the aseptic filling field. The ready-to-fill pre-sterilized syringes are inserted into nests of 160 pcs/each and automatically handled by sterile plastic tubs. The machine is equipped with a 100% checkweighing group, for net and gross weighing before/after filling and final relocation inside the nest. The syringes are filled and then stoppered five at a time. Dosing units and stopper pick and place arm are driven by brushless motors. The machine is designed to dispense liquids and stoppers either in conventional clean rooms or under RABS or isolators. Controlled by HMI with industrial PC, the machine can perform a speed up to 7,000 pcs/hour with 100% check weighting system. 

IMA’s liquid filling and closing machine is an innovative fill-finish concept to alternatively process ready-to-fill syringes, vials, and cartridges. The machine is designed for aseptic environments and suitable for barrier technology implementation. It can reach an output speed up to 1,300 pcs/hour. Combining filling, stoppering, and capping operations for a multiple range of different containers such as syringes, cartridges, and vials, this machine offers the reliability of a fully automated production line, minimizing space, and preserving sterility requirements. Dedicated mechanized arms ensure the completely fully automated product transfer/handling operations. All types of dosing systems, suitable for aseptic processing, can be installed on the machine.

Source: IMA, Hall 3.0, Stand F49